JP3030124B2 - Tile carpet and resin composition for lining the same - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a tile carpet used as flooring material for stores, offices, houses, and the like.

[0002]

2. Description of the Related Art A tile carpet is a small-area plate-shaped carpet that is set so as to constitute a floor covering surface of various widths and shapes by combining a plurality of tile carpets with a unit of laying. It has a basic structure in which a backing layer mainly composed of a synthetic resin is laminated on the back side of a carpet substrate made of a fiber material in which pile yarn is implanted.

However, in such a tile carpet, since the size per sheet is much smaller than that of a normal carpet, laying and carrying are easy, and partial replacement can be easily performed. In addition, it has the advantage that various design configurations are possible depending on the combination of colors and shapes, but it is necessary to prevent the edges from turning up and the gap and overlapping between adjacent carpets to maintain the aesthetic appearance in use. It is required to have sufficient adhesiveness to the floor and to be hard to cause a dimensional change due to a temperature change or a stress accompanying walking.

Therefore, conventionally, as a backing material for tile carpets, resin compositions such as asphalt-based, by-product atactic polypropylene-based, and polyvinyl chloride-based have been widely used to meet the above demand.

[0005]

However, the backing of the asphalt-based resin composition has the disadvantage that the hardness changes greatly with temperature, cracks easily occur at low temperatures, and the heat resistance is poor. In the backing with the by-product atactic polypropylene-based resin composition, atactic polypropylene is a by-product of the production of crystalline isotactic polypropylene resin, and has a stable softening point, melt viscosity, and other properties. As a result, the quality of the backing layer and the heat resistance of the backing layer vary greatly and cannot maintain a constant quality, and the low-temperature properties are inferior. In addition, the backing of the polyvinyl chloride resin composition generates a large amount of toxic hydrogen chloride gas when burned and generates a large amount of toxic hydrogen chloride gas, so there is a high risk of fire, and the waste carpet was incinerated. In such a case, there is a problem that a highly toxic chlorine compound is generated to cause environmental pollution and that the incinerator is easily damaged.

In view of the above situation, the present invention is stable in quality, does not crack the backing layer even at a low temperature, has high pile fixing strength, has excellent heat resistance, and emits little smoke during combustion. It is intended to provide a tile carpet that does not generate poison gas.

The inventors of the present invention have conducted intensive studies to achieve the above object, and as a result, have found that amorphous propylene / ethylene random copolymer or amorphous polypropylene is mainly used.
A resin composition in which a specific resin component containing an alicyclic petroleum resin as a tackifier and a filler composed of calcium carbonate and magnesium hydroxide in a specific ratio is used as a backing material. The present invention has been found to provide a tile carpet that has excellent low-temperature characteristics and heat resistance, is stable in quality, has low smoke and generates no toxic gas even when burned, and can provide a very excellent tile carpet. Reached.

[0008] That is, one aspect of the present invention is to provide a main polymer consisting of amorphous propylene / ethylene random copolymer or / and amorphous polypropylene on the back side of a carpet base material, and a weight ratio of 5 to the main polymer. The average is based on 100 parts by weight of a resin component containing 15% of crystalline polypropylene and 10 to 40% of an alicyclic petroleum resin-based tackifier.
Calcium carbonate 170-29 having a particle size of 1-500 μm
A tile carpet comprising a backing layer made of a resin composition in which 0 parts by weight and 10 to 100 parts by weight of magnesium hydroxide are mixed in a range of a total of 300 parts by weight or less. Another one is a gist of the resin composition for lining a tile carpet according to the above composition.

[0009]

DETAILED DESCRIPTION OF THE INVENTION The backing layer to be placed on the tile carpet of the present invention is formed by applying a hot-melt mixture of the resin composition comprising the resin component and the filler component to the back side of the carpet substrate. I do.

The amorphous propylene / ethylene random copolymer and the amorphous polypropylene used as the main polymer of the resin component are, for example, hydrogen-existing using a titanium-supported catalyst using magnesium chloride as a carrier and triethylaluminum. The former is obtained by introducing ethylene into liquefied propylene and copolymerizing it, and the latter is obtained by performing a polymerization reaction without introducing ethylene. Therefore, since the main polymer is produced differently from the conventional by-product atactic polypropylene, it is necessary to stably obtain a polymer having various properties such as a softening point and a melt viscosity within a certain range. The softening point, the melt viscosity and the like can be set to desired values by adjusting the copolymerization ratio and the molecular weight.

The above-mentioned amorphous propylene / ethylene random copolymer and amorphous polypropylene have a number average molecular weight of 1,000 to 20,000, preferably 1,50.
0 to 18,000. If it is less than 1,000, sufficient cohesion and mechanical strength cannot be obtained, and 20,000
If it is larger, the melt viscosity becomes too high, and it becomes difficult to process the backing layer of the tile carpet. The amorphous propylene / ethylene random copolymer has an ethylene content of 30% or less. If it is more than 30%, the softening point is too low to make it too soft or the surface is sticky, which is not preferable as a material for the backing layer.

Crystalline polypropylene used as a resin component together with the main polymer increases the softening point of the resin composition to improve heat resistance, and also enhances cohesive force to prevent deformation due to load when using a carpet. It is responsible for. As such a crystalline polypropylene, other than a homopolymer of propylene, a copolymer mainly composed of propylene is included, and any commercially available polypropylene can be used, and particularly, a melt index (230 ° C.) Those having a melt index of from 15 to 50 are preferred. If the melt index is too low, it takes a long time to melt at the time of heating and mixing, and the melt viscosity of the mixture becomes high, thereby deteriorating the processability and, conversely, being too high. In such a case, the cohesive force of the resin composition becomes insufficient.

The amount of the crystalline polypropylene is in the range of 5 to 15% by weight based on the main polymer. If the amount is less than 5% by weight, the heat resistance and the cohesive force of the backing material become insufficient, and conversely, the amount of 15% by weight. If the ratio exceeds the above range, the melt viscosity of the resin composition will increase, leading to deterioration in workability.

The tackifier of the resin component lowers the melt viscosity of the resin composition to allow a large amount of filler to be blended, and enhances the adhesion to the carpet base material by the adhesive action.
It has a function of preventing interfacial peeling between the carpet base material and the backing layer when the carpet is in use. In the present invention, an alicyclic petroleum resin-based tackifier is used. That is, as the tackifier other than the alicyclic petroleum resin, natural rosin, modified rosin, coumarone-indene resin, terpene resin, phenol resin, and the like are generally known, but these other tackifiers are used. If it is, there is a drawback that smoke during combustion increases.

The amount of the alicyclic petroleum resin-based tackifier is in the range of 10 to 40% by weight based on the main polymer. When the amount is less than 10% by weight, the melt viscosity of the resin composition is reduced. Is not sufficiently exhibited, the workability when a large amount of filler is blended is deteriorated, and the adhesion to the carpet base material becomes insufficient. On the other hand, if it exceeds 40% by weight, the backing layer becomes sticky and the carpet surface or floor is The surface is easily stained, and smoke generated during combustion increases.

On the other hand, in the present invention, calcium carbonate and magnesium hydroxide are used as fillers to be mixed with the resin composition of the backing layer as described above.
It is used for the purpose of improving dimensional stability, reducing the price of the entire resin composition, and the like, and the latter is used for reducing the amount of smoke generated during combustion. In addition, clay, talc, barium sulfate, calcium sulfate, and the like are fillers that can be expected to have the same effect as the former calcium carbonate, but calcium carbonate is superior in price and availability. Aluminum hydroxide is known as a filler used for the same purpose as the magnesium hydroxide of the latter, but its thermal decomposition point is 200.
Since it is about ° C, decomposition occurs during heating and mixing, which is inconvenient.

As the above calcium carbonate , those having an average particle diameter in the range of 1 to 500 μm are used . If the average particle size is too small, the melt viscosity of the resin composition increases, resulting in deterioration of workability. Conversely, if the average particle size is too large, cracking due to deformation of the backing layer is likely to occur when a large amount is blended. In particular
Desirable is a range of 10 to 150 μm.
You .

However, the total amount of calcium carbonate and magnesium hydroxide should be in the range of 180 to 300 parts by weight based on 100 parts by weight of the resin component. If the effect of increasing the softening point of the product becomes insufficient, and if it exceeds 300 parts by weight, the melt viscosity of the resin composition increases, thereby deteriorating the processability and easily causing cracks in the backing layer. It is desirable to increase the ratio of magnesium hydroxide in the above total amount for the purpose of suppressing smoke emission during combustion. However, magnesium hydroxide generally has a small average particle diameter of 10 μm or less, and has a high melt viscosity due to a large amount. Therefore, the upper limit of the amount is set to 100 parts by weight of the total amount, and the lower limit is set to 10 parts by weight in order to impart a sufficient smoke suppressing effect. Therefore, the other calcium carbonate is 170 to 170% of the total amount.
The range is 290 parts by weight.

In the present invention, in addition to the resin component and the filler, additives such as a coloring agent and various modifiers may be added in a small amount to the resin composition of the backing layer, if necessary.
The colorant is preferably used in the form of a masterbatch blended with a highly soluble olefin base polymer or the like in order to enhance dispersibility during melt mixing. Examples of the modifier include a high-boiling oil for improving low-temperature characteristics.

In order to produce the tile carpet of the present invention, the above resin composition is heated on the back side of a fiber carpet base material having a raised surface such as a pile yarn, preferably undercoated with latex or the like. The molten mixture is applied to a predetermined thickness, cooled and hardened to form a backing layer having a thickness of about 2.5 to 4 mm, and then cut or punched as necessary to obtain a predetermined size as a tile carpet,
What is necessary is just to be a shape. Thus, as a particularly preferred configuration of the tile carpet of the present invention, a configuration in which a backing layer made of the resin composition is used as a plurality of upper and lower layers and an intermediate base fabric made of glass fiber is interposed between the layers, in this case, There is an advantage that the dimensional stability of the carpet is further improved by the presence of the intermediate base fabric.

[0021]

EXAMPLES Examples of the present invention will be specifically described below in comparison with comparative examples. In the following, “parts” means “parts by weight”.

Examples 1 to 3 Amorphous propylene / ethylene random copolymer (RT2215 manufactured by Ube Lexen Co., Ltd., melt viscosity 1500 cps, softening point 143 ° C.) or amorphous polypropylene (Ube Lexen Co., Ltd.) RT2115, melt viscosity 1500 cps, softening point 152 ° C.) was put into a heating melting pot, heated to 190 ° C. while stirring with a mixer, and melted. Then, the amount of crystalline polypropylene shown in Table 1 (manufactured by Ube Industries) J130G, homopolymer, melt index 30) and alicyclic petroleum resin (T by Mitsui Petrochemical Industries, Ltd.)
300X, softening point 95 ° C) gradually, and heating temperature 1
The mixture was uniformly melted at 70 to 190 ° C., and calcium carbonate (G # 10 manufactured by Sankyo Seiko Co., Ltd.) was added in the amount shown in Table 1.
0, average particle diameter 60 μm) and magnesium hydroxide (HTR-D manufactured by Ube Chemical Co., Ltd., average particle diameter 100 μm)
And gradually mixed at a heating temperature of 190 ° C.
A backing resin composition was prepared. Next, a carpet base material (5 mm in thickness) manufactured by Sumie Textile Co., Ltd. on which pile yarn was implanted
After applying the above-mentioned resin composition for backing to a thickness of 1.4 mm with a doctor knife on the back surface previously treated with latex with a latex, and bonding a 0.5 mm-thick glass fiber intermediate base fabric thereon, Further, the above-mentioned resin composition for backing was applied to a thickness of 1.4 mm, cooled and cured to form a backing layer, and finally cut into a size of 50 × 50 cm to prepare a tile carpet.

Comparative Examples 1 to 6 Tile carpets were produced in the same manner as in the Examples except that the composition of the backing resin composition was changed to the composition shown in Table 1 below. The atactic polypropylene in Table 1 is a commercially available product (melt viscosity 2000 cps, softening point 140
C), and P125 (softening point 125 ° C) manufactured by Yasuhara Yushi Kogyo Co., Ltd. was used as the terpene resin.

Comparative Example 7 100 parts of dioctyl phthalate and 100 parts of polyvinyl chloride paste resin (P410, homopolymer manufactured by Mitsubishi Kasei Vinyl Co., Ltd.) were stirred in a stirring vessel, and then 300 parts of calcium carbonate (described above) were charged. Stir and mix uniformly,
A resin composition for backing was prepared. Next, the composition was applied on a release sheet to a thickness of 1.4 mm, and an intermediate base fabric made of glass fiber (same as in the example) was stuck thereon. After applying the same carpet base material on the back surface side, heating to 160 ° C., cooling, and releasing the release sheet, the same as in the example. It was cut into a size to produce a tile carpet.

[0025]

[Table 1]

Regarding the tile carpets of the above Examples and Comparative Examples, dimensional stability, low-temperature characteristics, thread pulling strength, properties of the backing layer, melt viscosity of the backing resin composition (excluding Comparative Example 7), smoke emission, and combustion The results of measuring the gas analysis values are shown in Table 2 below. In addition, the measuring method and evaluation of each item are as follows.

[Dimensional Stability] The heating / cooling cycle of heating at 60 ° C. for 2 hours and cooling at −20 ° C. for 2 hours is two times.
It was measured after 5 repetitions.

[Low-temperature characteristics] Carpet having a diameter of 20 mm
Was bent so that the back surface side was outside along the rod, and the presence or absence of cracks was observed.

[Thread Yield Strength] Measured according to JIS L1021.

[Properties of Backing Layer] A sample having a uniform thickness and no stickiness was designated as A, a sample having a non-uniform thickness as B, and a sample having stickiness as C.

[Melt Viscosity] The melt viscosity was measured with a BL-type rotational viscometer.

[Smoke emission] NBS (ASTM E66)
2) Ds (SMOKE DE) measured by the chamber method
(NSITY) value.

[Combustion gas analysis] Measurement was performed by a gas detector tube method of the NBS chamber method.

[0034]

[Table 2]

[0035]

According to the present invention, a tile carpet having a thermoplastic resin backing layer on the back side of a carpet base material has excellent dimensional stability, low-temperature characteristics, and heat resistance. even under load due to temperature changes or walking in the state, up curling end, gaps or overlaps between adjacent carpet without causing cracks or the like of the backing layer, rather stickiness of the backing layer, manufactured in 且 single inexpensive Easy things can be provided. In addition, contains magnesium hydroxide in a specific ratio
Alicyclic petroleum resin as a tackifier
Smoke generated by combustion is fully suppressed
can do. In addition, this backing resin composition is
The generation of toxic gas is small. Therefore as little smoke and generation of toxic gas by combustion, a low risk of a fire, risk of environmental pollution yet name by incineration.

Continuation of the front page (51) Int.Cl. ⁷ Identification code FI D06N 3/04 D06N 3/04 (72) Inventor Iwao Tsuruya 1-32 Akasaka, Minato-ku, Tokyo Ark Mori Building 20F Ube Lexen Co., Ltd. 72) Inventor Takafumi Manabe 3-1 Chikko Shinmachi, Sakai City, Osaka Prefecture Ube Industries, Ltd. Sakai Plant (56) References JP-A-3-124488 (JP, A) JP-A-61-128916 (JP, A) (58) Field surveyed (Int.Cl. ⁷ , DB name) A47G 27/02 B32B 27/12 C08K 3/20 C08K 3/26 C08L 23/16 D06N 3/04

Claims (2)

(57) [Claims] 1. A main polymer comprising amorphous propylene / ethylene random copolymer or / and amorphous polypropylene, and 5-15% by weight of crystalline polypropylene on the back side of the carpet substrate. 10-40
% Of an alicyclic petroleum resin-based tackifier
With respect to 00 parts by weight, 170 to 290 parts by weight of calcium carbonate having an average particle diameter of 1 to 500 μm and 10 to 100 parts by weight of magnesium hydroxide in a range where the total of both is 300 parts by weight or less A tile carpet comprising a backing layer made of a compounded resin composition. 2. A main polymer comprising an amorphous propylene / ethylene random copolymer and / or an amorphous polypropylene, and a weight ratio of 5 to 15% of a crystalline polypropylene and 10 to 40% of an alicyclic group to the main polymer. relative to 100 parts by weight of the resin component containing a system petroleum resin tackifiers, average particle
Calcium carbonate with a diameter of 1 to 500 μm 170 to 290
Part by weight and 10 to 100 parts by weight of magnesium hydroxide, a resin composition for lining a tile carpet, which is blended in a range of a total of 300 parts by weight or less.